Air Distribution Housing

HOUSING-AIR DISTRIBUTION

NOTE: The air distribution housing must be removed from the HVAC housing and disassembled for service of the blend-air and mode-air doors.

NOTE: LHD model with A/C shown in illustrations. RHD and heater-only models similar.





1. Remove the HVAC housing assembly and place it on a workbench HVAC Housing - Removal.
2. Remove the air distribution housing (2) from the HVAC housing (1) HVAC Housing - Removal.
3. If equipped with the 2.0L diesel engine, remove the electric positive temperature coefficient (PTC) heater unit from the air distribution housing .
4. Remove the heater core from the air distribution housing Removal.





5. Remove the temperature control cable (1) from the left side of the air distribution housing (2) Temperature Door Cable - Removal.
6. Remove the screw and washer (5) that secures the blend door cable lever (6) to the air distribution housing and remove the cable lever.

NOTE: To remove the blend door pivot lever, disengage the retaining tab and pull the lever straight out of the air distribution housing.

7. Remove the blend door pivot lever (3) from the end of the blend door pivot shaft (4) and remove the pivot lever.





8. Remove the mode door cable (1) from the right side of the air distribution housing (2) Mode Door Cable - Removal.
9. Remove the screw and washer (3) that secure the mode door cam (4) to the air distribution housing and remove the cam.






NOTE: If any foam seal on the air distribution housing outlets is deformed or damaged, the seal must be replaced.

10. Carefully cut the two foam seals (1) along the parting line (2) of the two halves of the air distribution housing (3). If either seal is deformed or damaged, it must be replaced.
11. Remove the five screws (4) and one metal clip (5) that secure the two halves of the air distribution housing together.
12. Disengage the three plastic retaining tabs (6) that secure the two halves of the air distribution housing together and carefully separate the housing.






NOTE: If a seal on an air door is deformed or damaged, the air door must be replaced.

13. Disengage the air door(s) (1, 2, 3 and 4) from the mode door levers and remove the air doors from the air distribution housing (5).






NOTE: To remove the mode door levers, disengage the retaining tabs on the inside of the air distribution housing and pull the levers straight out of the housing.

14. Remove the four mode door levers (1, 2, 3 and 4) from the right side of the air distribution housing (5).